Tool clamping system with variable tool length

Challenge from industrial production

Long cutting tools are required for the production of components with deep cavities or poor cutting tool accessibility by milling. However, long cutting tools have low rigidity and are prone to vibration. For this reason, machining operations with long tools in manufacturing companies are carried out particularly slowly and with very small feed rates in order to keep the machining forces low and minimize the vibrations that occur. However, this slows down the production process considerably, which results in a significant increase in tool costs, machine hours and thus the manufacturing costs of the component. 

Solution path in the research project

In the Pinocchio research project, we and our project partners have developed a toolholder clamping system that allows the cutting tool length to be automatically changed during machining: The tool length can be varied as required during the machining process. If at the beginning of the machining process the overhang length may still be small, the short tool length can be used for very fast and economical machining. As soon as longer tools are required, the overhang length is increased by the tool holder and the process can continue to be carried out at the economic optimum.